Actuator for an aerosol container

ABSTRACT

An actuator for an aerosol container, comprising a body forming an inlet, a top surface (16) defining a multitude of discharge slits (20), and a multitude of body passageways (22) to conduct fluid from the inlet to the discharge slits. Each of the body passageways has a pouch shape, including narrower upper (22a) and lower portions (22b) and a wider mid portion (22c). When the actuator is used to dispense foam from an aerosol container, the shape of the body passageways has several advantages. First, that shape helps the foam to expand as it passes outward through the dispenser, and second, after the container has ben used to dispense a quantity of foam, the shape of the body passageways helps to draw back into the actuator any excess foam remaining on the outside of the actuator. Preferably, the actuator is formed in a plastic injection molding process, and the body passageways of the actuator are formed into the desired shape as the plastic cools during the molding process.

This application in a division of U.S. application Ser. No. 08/557,059 filed Mar. 8, 1996 now U.S. Pat. No. 5,730,332, which was the National Stage of International Application No. PCT/EP93/03464 filed Dec. 9, 1993, which claims the benefit of International Application No. PCT/EP93/01293 filed May 24, 1993.

BACKGROUND OF THE INVENTION

This invention generally relates to actuators or spouts for pressurized packages commonly referred to as aerosol containers, and more specifically, to such actuators that are particularly well suited to dispense foam from aerosol containers.

Aerosol packages typically comprise a pressurized container that holds a fluid or solution, and a valve unit to dispense the fluid or solution from the container. The valve unit is situated in the neck of container and is opened by finger pressure against an actuator that is disposed at one terminal end of a valve stem. The valve unit has a moveable valve body and an associated hollow valve stem that, upon the application of the above-mentioned finger pressure, unseats from a gasket to permit flow of product into the valve stem and then through and from the actuator.

Many aerosol containers are used to dispense a foam that is used for personal or household purposes, such as mousse. It is known that the texture or quality of foams emerging from pressurized foam containers can be improved by making the foam pass through narrow passageways in the actuators of the containers. Heretofore, typically, in order to provide an actuator with a multitude of such narrow passageways, it has been necessary to make the actuator from two or more pieces that are made separately and then joined or fitted together. Despite the associated economic advantages, no commercially practical process has been developed for forming a one-piece, integrally molded actuator having a multitude of narrow passageways.

Another disadvantage of prior art foam actuators is that often, after the actuator is used to dispense a quantity of foam, a small amount of that foam remains on the surface of the actuator. Over a period of time, that foam collapses and dries, leaving a sticky residue on the actuator that is both messy and unsightly.

SUMMARY OF THE INVENTION

An object of this invention is to improve actuators for aerosol containers.

Another object of the present invention is to provide an actuator that is able to draw foam back inward, into the actuator, after the actuator has been used to dispense a quantity of foam from an aerosol container.

A further object of this invention is to provide a one-piece, integrally molded actuator for dispensing foam from an aerosol container and having a multitude of narrow passageways that act to improve the texture and quality of the foam dispensed from the container.

Another object of this invention is to form a foam actuator in a plastic injection molding process, and to utilize the natural shrinkage that occurs during the molding process to form pouch-shaped passageways in the actuator that both improve the texture and quality of the foam discharged from the actuator, and also help to draw back into the actuator foam residue from the actuator surface.

These and other objectives are attained with an actuator for an aerosol container, comprising a body forming an inlet, a top surface defining a multitude of discharge slits, and a multitude of body passageways to conduct fluid from the inlet to the discharge slits. Each of the body passageways has a pouch shape, including narrower upper and lower portions and a wider mid portion. Preferably, the discharge slits and the body passageways radially extend outward from, and are equally spaced apart around, a central portion of the body with one embodiment, that central portion comprises a solid stem; and in another embodiment, that central portion forms a conduit that extends between the inlet and the top surface of the body to help discharge foam from the actuator.

When the actuator is used to dispense foam from an aerosol container, the shape of the body passageways has several advantages. First, that shape helps the foam to expand as it passes outward through the actuator; and second, after the container has been used to dispense a quantity of foam, the shape of the body passageways helps to draw back into the actuator any excess foam remaining on the outside of the actuator. Preferably, the actuator is formed in a plastic injection molding process, and the body passageways of the actuator are formed into the desired shape as the plastic cools during the molding process.

Further benefits and advantages of the invention will become apparent from a consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an actuator, with portions broken away, embodying the present invention.

FIG. 2 is a cross-sectional view of the actuator, taken along plane II--II of FIG. 1.

FIG. 3 is a front view of the actuator.

FIG. 4 is a back view of the actuator.

FIG. 5 is a top view of the actuator.

FIG. 6 is a perspective view of an alternate embodiment of the actuator, also with portions broken away.

FIG. 7 is a cross-sectional view of the actuator of FIG. 6, taken along plane VII--VII thereof.

FIG. 8 is a simplified view illustrating a mold for making the actuator shown in FIGS. 1-5.

FIG. 9 illustrates a portion of a mold for making the actuator of FIGS. 6 and 7.

FIG. 10 shows a portion of the actuator formed in the mold of FIG. 8.

FIG. 11 shows the actuator portion of FIG. 10 after the actuator has cooled.

FIG. 12 shows the actuator of FIGS. 1-5 assembled in a valve for an aerosol container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-5 illustrate an actuator or spray spout, generally designated at 10, for an aerosol container. Actuator 10 comprises body 12 that forms inlet 14, top surface 16 that defines a multitude of elongated discharge slits 20, and a multitude of body passageways 22. Preferably, actuator body 12 also forms central stem 24, outside shell 26 including a lower mounting section 26a, and a finger or actuator surface 30. As discussed below, preferably actuator body 12 is a one-piece body formed in an injection molding process.

Inlet 14 is provided to connect actuator 10 to the valve stem of an aerosol valve, in fluid communication therewith. Each of the body passageways 22 extends between inlet 14 and a respective one of the discharge slits 20 to conduct foam from the body inlet to that discharge slit, through which the fluid is then discharged from the actuator. Shell 26, particularly mounting section 26a, is provided to mount actuator 10 on an aerosol container. Surface 30 provides an area for a user to apply finger pressure to actuator 10 to open the valve stem to which the actuator is connected and thereby dispense fluid through the actuator.

With particular reference to FIGS. 1 and 11, each passageway 22 of actuator body 12 has a pouch shape, including narrower upper and lower portions 22a and 22b and a wider intermediate or middle portion 22c. More specifically, the upper and lower portions 22a and 22b of each passageway 22 have a width generally equal to the width of the discharge slits 20. The sidewalls 32a and 32b of each passageway 22 extend downwardly and outwardly from the top of the passageway, forming the enlarged central portion 22c of the passageway; and from this central portion, the sidewalls of each passageway extend downwardly and inwardly, narrowing the width of the passageway.

The unique shape of passageways 22 of actuator 10 has several advantages. First, when the actuator is used to dispense foam from an aerosol container, the enlarged portions of the body passageways help that foam to expand, improving the texture and quality of the foam. Second, after the actuator has been used to dispense a quantity of foam, the foam remaining in passageways 22 partially collapses, producing an appreciable vacuum that draws foam back into the passageways from top surface 16 of the actuator. This helps to keep that top surface clean and free of excess foam, eliminating the sticky residue that can be produced by any foam remaining on that surface.

FIGS. 6 and 7 show an alternate actuator 34 having a central conduit 36 in place of stem 24. More particularly, actuator 34 is very similar to actuator 10, and like reference numbers are used to identify identical or corresponding elements of the two actuators. Thus, actuator 34 includes body 12 that forms inlet 14, and top surface 16 that defines a multitude of body passageways 22. Preferably, actuator body 12 of actuator 34 also forms outside shell 26 including lower mounting section 26a, and finger or actuator surface 30. Inlet 14, body surface 16, discharge slits 20, body passageways 22, shell 26, and actuator surface 30 of actuator 34 serve the same functions as the corresponding elements of actuator 10. Also, preferably, body passageways 22 of actuator 34 have pouch shapes, including narrower upper and lower portions 22a and 22b and a wider intermediate or middle portion 22c. In addition, body 12 of actuator 34, like body 12 of actuator 10, is preferably a one-piece body formed in an injection molding process.

Actuators 10 and 34 differ, as mentioned above, in that the latter actuator has a central conduit 36, including a top outlet opening 36a, where the former actuator has stem 24. More specifically, in actuator 34, conduit 36 extends between and is in fluid communication with inlet 14 and top outlet 36a, and preferably discharge slits 20 and body passageways 22 extend radially outward from and are in fluid communication with conduit 36.

When actuator 34 is used to discharge product from an aerosol container, the product evenly spreads through all the cavities 22 of the radical slots 20, as well as into the central conduit 36. In this way, conduit 36 facilitates the discharge of foam from actuator 34. That central conduit 36 also helps to draw residue foam back into the actuator. In addition, when used with an aerosol container having a high percentage of propellant or a propellant of high pressure, the central conduit 36 of actuator 34 dramatically reduces the noise level caused by the discharge or spray of product from the aerosol container.

Preferably, as previously mentioned, actuators 10 and 34 are formed in injection molding processes and FIGS. 8 and 9 are simplified illustrations of molds 38 and 40 for forming actuators 10 and 34. With reference to FIG. 8, mold 38 includes first, second, and third parts 42, 44, and 46 that, when brought together as shown in FIG. 8, form a recess or cavity 48 substantially having the shape of actuator 10. A multitude of blades 50 or similar means are connected to mold part 46 to form discharge slits 20 and body passageways 22, and these blades may be retractable into mold part 46.

Mold 40 is very similar to mold 38 and includes a plurality of parts 52, 54, and 56 that, when brought together as shown in FIG. 9, form a recess or cavity 58 substantially having the shape of actuator 34. A principal difference between molds 38 and 40 is that the latter mold includes a stem 60 that is used to form central conduit 36 of actuator 34. Mold 40, like mold 38, may include a multitude of retractable blades 62 or similar means connected to mold part 56 to form the discharge slits 20 and the body passageways 22 of actuator 34.

To form actuator 10, mold parts 42, 44, and 46 are brought together to form cavity 48, and then a hot molten plastic is injected into the mold cavity to fill that cavity. Similarly, to form actuator 34, mold parts 52, 54, and 56 are brought together to form cavity 58, and a hot molten plastic is injected into that mold cavity to fill the cavity. In both cases, after the cavity is filled with the plastic, the mold is cooled to harden the plastic. As the plastic cools, the upper portions of the actuator body 12 shrink from an initial shape, shown at 64 in FIG. 10, to a final shape, shown at 66 in FIG. 11, thus forming enlarged portions 22c of passageways 22. Once the plastic has sufficiently hardened, the mold is opened and the actuator is removed.

The above-mentioned shrinkage of the plastic material is normally undesirable, and usually efforts are made to prevent or minimize this shrinkage. The present invention employs this normally undesirable effect to actually improve the design and operation of the actuator.

FIG. 12 shows actuator 10 assembled in an aerosol valve 70, which also includes mounting cup 72, valve body 74, valve stem 76, valve housing 80, spring 82, and gasket 84. The mounting cup 72 is shown partially cut away, and valve housing 80 is crimped to the mounting cup. Gasket 84 is disposed between the top of valve housing 80 and mounting cup and 72 extends around a central, top opening in the mounting cup. Valve stem 76 extends through this top opening and through gasket 84, and the valve stem forms a fluid passageway 76a that extends upward to the valve outlet 76b. The lower sidewall of valve stem 76 forms a through opening 76c that, as shown in FIG. 12, is closed by gasket 84. Valve body 74 is connected to the lower end of valve stem 76, and the valve body is biased upwardly, into engagement with gasket 84, by spring 82, which is disposed between the bottom of the valve body and a surface of valve housing 80. Valve body 74 forms one or more openings that form fluid passageways between the exterior and interior of the valve body.

Aerosol valve 70 is of the type that is designed to be used in an inverted position. In particular, the valve is intended to be mounted on the top of an aerosol container that is inverted to dispense fluid downwardly from the container and through valve 70. For this reason, the bottom of valve housing 80 forms one or more openings 86 to conduct fluid into the valve housing from the associated aerosol container. As will be understood by those of ordinary skill in the art, valve housing 80 may be easily modified for use in an upright position; and specifically, this may be done by providing the valve housing with a conventional inlet, and connecting a conventional dip tube to that inlet to conduct fluid upward into the valve housing from an associated aerosol container.

In use, valve 70 is mounted on an aerosol container and fluid from that container passes into valve housing 80. Normally, valve 70 is in the position shown in FIG. 12, in which gasket 84 closes opening 76c of valve stem 76 and prevents fluid from passing from housing 80 and into the valve stem. To discharge fluid from the aerosol container, actuator 10 is press downward (as viewed in FIG. 12), moving valve stem 76 and valve body 74 downward. This moves side opening 76c of valve stem 76 away from gasket 84, allowing the fluid to pass into the valve stem and then through actuator 10, which discharges the fluid.

As will be understood by those of ordinary skill in the art, actuator 34 may be assembled in aerosol valve 70 in a manner substantially identical to the way in which actuator 10 is assembled in that aerosol valve.

While it is apparent that the invention herein disclosed is well calculated to fulfill the objects previously stated, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention. 

I claim:
 1. An injection molding process for forming an actuator for an aerosol container, comprising:injecting a plastic material into a mold to form a body havingi) an inlet to connect the actuator to a discharge outlet of the container, in fluid communication therewith, to receive fluid therefrom, ii) a top surface defining a multitude of elongated discharge slits to discharge fluid from the actuator, and iii) a multitude of body passageways extending between the inlet and a respective one of the discharge slits to conduct the fluid from the inlet to said one of the discharge slits, the body passageways being formed in an upper massive part of the body; cooling the plastic material, wherein portions of the plastic material shrink and enlarge intermediate portions of the body passageways between the inlet and the discharge slits; and removing the plastic material from the mold.
 2. A process according to claim 1, wherein the cooling step includes the steps of forming each body passageway with a narrow upper portion, a narrow lower portion and a wider mid portion.
 3. A process according to claim 1, wherein the mold has a series of internal blades, and the injecting step includes the steps of:injecting the plastic material around the series of blades;and removing the blades from the plastic material to form initial shapes for the elongated discharge slits and the body passageways.
 4. A process according to claim 1, wherein the injecting step includes the step of forming a central stem in said body, with the multitude of elongated discharge slits and the multitude of body passageways radially extending outward from said central stem.
 5. A process according to claim 1, wherein the injecting step includes the steps of forming a central top outlet opening in said top surface and forming a central conduit extending between the inlet and said central top outlet, with said multitude of body passageways disposed around said central conduit.
 6. A process according to claim 5, wherein the injecting step includes the step of forming the body with the multitude of body passageways in fluid communication with and radially extending outward from said central conduit. 